US20080200049A1 - Overmolded Electrical Contact Array - Google Patents
Overmolded Electrical Contact Array Download PDFInfo
- Publication number
- US20080200049A1 US20080200049A1 US11/677,449 US67744907A US2008200049A1 US 20080200049 A1 US20080200049 A1 US 20080200049A1 US 67744907 A US67744907 A US 67744907A US 2008200049 A1 US2008200049 A1 US 2008200049A1
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- US
- United States
- Prior art keywords
- housing
- connector
- tail
- leadframe
- protrusion
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/40—Securing contact members in or to a base or case; Insulating of contact members
- H01R13/405—Securing in non-demountable manner, e.g. moulding, riveting
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R12/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, specially adapted for printed circuits, e.g. printed circuit boards [PCB], flat or ribbon cables, or like generally planar structures, e.g. terminal strips, terminal blocks; Coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures; Terminals specially adapted for contact with, or insertion into, printed circuits, flat or ribbon cables, or like generally planar structures
- H01R12/70—Coupling devices
- H01R12/71—Coupling devices for rigid printing circuits or like structures
- H01R12/712—Coupling devices for rigid printing circuits or like structures co-operating with the surface of the printed circuit or with a coupling device exclusively provided on the surface of the printed circuit
- H01R12/716—Coupling device provided on the PCB
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R12/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, specially adapted for printed circuits, e.g. printed circuit boards [PCB], flat or ribbon cables, or like generally planar structures, e.g. terminal strips, terminal blocks; Coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures; Terminals specially adapted for contact with, or insertion into, printed circuits, flat or ribbon cables, or like generally planar structures
- H01R12/50—Fixed connections
- H01R12/51—Fixed connections for rigid printed circuits or like structures
- H01R12/55—Fixed connections for rigid printed circuits or like structures characterised by the terminals
- H01R12/58—Fixed connections for rigid printed circuits or like structures characterised by the terminals terminals for insertion into holes
- H01R12/585—Terminals having a press fit or a compliant portion and a shank passing through a hole in the printed circuit board
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/16—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for manufacturing contact members, e.g. by punching and by bending
Definitions
- the invention relates generally to electrical connectors. More particularly, the invention relates to connectors having tails.
- PCBs printed circuit boards
- PICMG AMC connectors may be used in accordance with such a specification.
- manufacturers of such connectors mold the contacts in a vertical (or “column”) direction. Accordingly, each column of contacts is molded into a separate leadframe assembly.
- IMLAs individual insert molded leadframe assemblies
- the invention provides a connector that incorporates a tail-alignment housing that may control the position of the mounting, or “tail,” ends.
- the tail-alignment housing may also provide a structure that helps absorb the forces required for press fitting the connector to a printed circuit board (PCB).
- the tail-alignment housing may have a housing body and a plurality of tail supports extending from the housing body up and around the contact tails.
- such a connector may include a first leadframe assembly having a first plurality of contacts, a second leadframe assembly having a second plurality of contacts, an edge card, and a tail-alignment housing.
- Each contact may include a lead portion and a mounting end. The lead portions of the contacts may engage the edge card.
- the tail-alignment housing may include a housing body and a plurality of tail supports extending from the housing body. The tail alignment housing may be overmolded onto the contact mounting ends.
- FIG. 1 is an isometric view of an embodiment of a first leadframe of electrical contacts as stamped and plated.
- FIG. 2 is an isometric view of a first leadframe assembly after molding.
- FIG. 3 is an isometric view of the leadframe assembly of FIG. 2 after forming and slugout.
- FIG. 4 is an isometric view of an embodiment of a second leadframe of electrical contacts as stamped and plated.
- FIG. 5 is an isometric view of a second leadframe assembly after molding.
- FIG. 6 is an isometric view of the leadframe assembly of FIG. 5 after forming and slugout.
- FIGS. 7A and 7B are isometric views of an embodiment of an edge card housing.
- FIG. 8 is an isometric view of an embodiment of a complete assembly prior to insertion into the edge card housing.
- FIG. 9 is an isometric view of the complete assembly of FIG. 8 with an edge card housing added.
- FIG. 10 depicts the complete assembly of FIG. 9 after a second overmold process.
- FIGS. 11A and 11B are isometric views of a portion of the complete assembly of FIG. 10 .
- FIG. 12 is a cross-sectional view of the complete assembly of FIG. 10
- FIG. 13 is an isometric view of the complete assembly of FIG. 10 with a left connector housing added.
- FIG. 14 is an isometric view of the complete assembly of FIG. 13 with a right connector housing added.
- FIG. 15 is an isometric view of an embodiment of a complete connector.
- a first embodiment leadframe 10 of electrical contacts 14 may be stamped from a sheet of electrically conductive material, such as copper alloy, for example.
- FIG. 1 depicts the leadframe 10 of electrical contacts 14 attached to one another and to a carrier frame 18 .
- Each contact 14 may include a mating end 22 , a mating portion 26 , a first housing portion 28 , a lead portion 29 , a second housing portion 30 , a third housing portion 32 , a mounting portion 34 , and a mounting end 36 .
- the lead portions 29 of the contacts may be attached to one another via “bridges” that remain after stamping.
- the mounting ends 36 of the contacts may each include a tail 38 .
- the contacts 14 may be selectively gold plated.
- first leadframe housing 42 may be overmolded onto the first housing portions 28 of the contacts 14 .
- a second leadframe housing 46 may be overmolded onto the second housing portions 30 of the contacts.
- Each leadframe housing may be made of a dielectric material, such as a plastic. Both housings may be overmolded onto the leadframe 10 in a single molding process using well-known techniques.
- FIG. 2 depicts a first leadframe assembly 48 after the first leadframe housing 42 and the second leadframe housing 46 have been overmolded onto the electrical contacts 14 , with the carrier frame 18 shown in FIG. 1 removed. As shown, a linear array 50 , or “row,” of electrical contacts 14 may extend through each of the first leadframe housing 42 and the second leadframe housings 46 .
- the second housing 46 may include one or more interlock members 54 .
- each interlock member 54 may be a protrusion 58 that extends from a face 60 of the housing 46 , or a recess 62 defined by the leadframe housing 46 .
- Each recess 62 is adapted to receive a complementary protrusion extending from a leadframe housing of a second leadframe assembly and each protrusion 58 is adapted to be received in a complementary recess defined by the leadframe housing of the second leadframe assembly.
- the interlock members 54 will be described in more detail in connection with FIG. 8 .
- FIG. 3 depicts an example embodiment of a leadframe assembly 48 after slug out and formation of the contacts 14 .
- the lead portions 29 may be bent to a first angle (e.g., 90°) at a first bend point 66 , to a second angle (e.g., 90°) at a second bend point 70 , and to a third angle (e.g., 90°) at a third bend point 74 .
- the lead portions 29 may be bent to include respective C-shaped portions that culminate in the respective mating portions 26 of the contacts 14 .
- the mating portions 26 of the contacts 14 may extend along a plane that is generally perpendicular to the plane along which the mounting portions 34 of the contacts 14 extend. In other words, the mating portions 26 of the contacts 14 may extend generally perpendicular to the mounting portions 34 of the contacts 14 .
- a second embodiment leadframe 110 of electrical contacts 114 may be stamped from a sheet of electrically conductive material, such as copper alloy, for example.
- FIG. 4 depicts the leadframe 110 of electrical contacts 114 attached to one another and to a carrier frame 1 18 .
- Each contact 114 may include a mating end 122 , a mating portion 126 , a first housing portion 128 , a lead portion 129 , a second housing portion 130 , a third housing portion 132 , a mounting portion 134 , and a mounting end 136 .
- the lead portions 129 of the contacts 114 may be attached to one another via “bridges” that remain after stamping.
- the mounting ends 136 of the contacts 114 may each include a tail 138 .
- the contacts 114 may be selectively gold plated.
- a first leadframe housing 142 may be overmolded onto the first housing portions 128 of the contacts 114 .
- a second leadframe housing 146 may be overmolded onto the second housing portions 130 of the contacts 114 .
- Each leadframe housing 142 / 146 may be made of a dielectric material, such as a plastic. Both the first leadframe housing 142 and the second leadframe housing 146 may be overmolded onto the leadframe 110 in a single molding process using well-known techniques.
- FIG. 5 depicts a second leadframe assembly 148 after the first leadframe housing 142 and the second leadframe housing 146 have been overmolded onto the electrical contacts 114 , with the carrier frame 118 shown in FIG. 4 removed. As shown, a linear array 150 , or “row,” of electrical contacts 114 may extend through each of the first leadframe housing 142 and the second leadframe housing 146 .
- the second housing 146 may include one or more interlock members similar to those described in connection with FIG. 2 .
- each interlock member may be a protrusion that extends from a face of the second leadframe housing, or a recess defined by the second leadframe housing.
- Each recess may be adapted to receive the complementary protrusion 58 extending from the second leadframe housing 46 of the first leadframe assembly 48 (see FIG. 3 ), and each protrusion may be adapted to be received in a complementary recess 62 defined by the second leadframe housing 46 of the first leadframe assembly 48 (see FIG. 3 ).
- the interlock members will be described in more detail in connection with FIG. 8 .
- FIG. 6 depicts an example embodiment of the leadframe assembly 148 after slug out and formation of the contacts 114 .
- the lead portions 129 may be bent to an angle (e.g., 90°) at a bend point 155 .
- the lead portions 129 may be bent to include respective L-shaped portions that culminate in the respective mating portions 126 of the contacts 1 14 .
- the mating portions 126 of the contacts 114 may extend along a plane that is generally perpendicular to the plane along which the mounting portions 134 of the contacts 114 extend. In other words, the mating portions 126 of the contacts 114 may extend generally perpendicular to the mounting portions 134 of the contacts 114 .
- FIGS. 7A and 7B depict an example edge card housing 180 .
- the edge card housing 180 may be made of a dielectric material, such as a plastic.
- the edge card housing 180 may include a row of receptacles 184 , a card slot 190 , an edge card body 194 , a first protrusion 196 extending from the left side of the edge card body 194 , a second protrusion 200 extending from the right side of the edge card body 194 , a third protrusion 204 extending from the bottom of the edge card body 194 and a recess 208 formed in the back side of the edge card body 194 .
- the first 196 , second 200 , and third 204 protrusions may be capable of being received by recesses formed in a connector housing.
- the recess 208 may be capable of receiving a protrusion extending from a connector housing.
- the first protrusion 196 and the second protrusion 200 may each consist of two snap-fit members, and the third protrusion 204 may consist of a T-beam or dove tail.
- the recess 208 formed in the back side may be a slot.
- the edge card 180 is not limited to the disclosed embodiment and may incorporate different designs and structures.
- FIG. 8 depicts an embodiment of the first leadframe assembly 48 and the second leadframe assembly 148 interlocked together creating a complete assembly 240 .
- Each recess 62 (as shown in FIG. 3 ) of the first leadframe assembly 48 may receive the respective protrusion from the second leadframe assembly 148 and each recess of the second leadframe assembly 148 may receive the respective protrusion 58 (as shown in FIG. 3 ) from the first leadframe assembly 48 .
- the first leadframe housing 142 of the second leadframe assembly 148 may rest on or connect to the first leadframe housing 42 of the first leadframe assembly 48 .
- the mounting portions 34 / 134 of each leadframe assembly may be parallel.
- the first leadframe assembly 48 may be inserted into the edge card housing 180 . That is, the mating portions 26 of the contacts 14 of the first leadframe assembly 48 may be received into the row of receptacles 184 defined by the edge card housing 180 .
- the second leadframe assembly 148 may be inserted into the edge card housing 180 . That is, the mating portions 126 of the contacts 114 of the second leadframe assembly 148 may be received into the row of receptacles 184 defined by the edge card housing 180 .
- FIG. 9 depicts an embodiment of the complete assembly 240 with both leadframe assemblies inserted into an example edge card housing 244 .
- a tail alignment housing 250 may be overmolded onto the third housing portions 32 / 132 of the contacts 14 / 114 , using well-known injection molding techniques.
- the tail alignment housing 250 may be made of a dielectric material, such as a plastic.
- FIG. 10 depicts an embodiment of the complete assembly 240 after the second overmold process. As shown, the tail alignment housing 250 may extend up a portion of the mounting ends 36 / 136 (as shown in FIG. 12 ) of both leadframe assemblies. Therefore, the tail alignment housing 250 may serve to control the position of the tails 38 / 138 of the mounting ends 36 / 136 and may provide a structure to transfer the forces for press fit of the connector to the PCB.
- an embodiment of a tail alignment housing 252 may include a plurality of tail supports 254 extending from a body 258 of the tail alignment housing 252 up and around the mounting ends 36 / 136 , that may help further control the position of the tails 38 / 138 and may provide further structure to the connector.
- the tail supports 254 may take the shape of pyramids, as shown in FIGS. 11A and 11B but are not limited to such a design.
- the supports may also be cones, squares, rectangles, or any other designs capable of controlling the position of the tails 38 / 138 .
- the tail alignment housing 252 may also have a first protrusion 260 extending from a left side 264 and a second protrusion 268 (shown in FIG. 13 ) extending from a right side 270 .
- the protrusions may be received by recesses formed in the connector housing.
- FIG. 12 depicts a cross-sectional view of the complete assembly 240 after the second overmold process, showing how the contacts may be oriented within the edge card 244 , and the tail alignment housing 250 .
- the mating portions 26 of the first leadframe assembly 48 may angle in a substantially upward direction within the edge card 244
- the mating portions 126 of the second leadframe assembly 148 may angle in a substantially downward direction within the edge card 244 .
- the mating ends 22 of the first leadframe assembly 48 may angle in a substantially downward direction
- the mating ends 122 of the second leadframe assembly 148 may angle in a substantially upward direction.
- the mating ends may extend toward the card slot of the edge card 244 .
- a connector housing may also be added to the complete assembly.
- the connector housing may be made of a dielectric material such as a plastic.
- the connector housing may be separated into two pieces; a left connector housing 274 and a right connector housing 278 .
- the left connector housing 274 may have a front wall portion 280 having a recess (not shown), a left side wall 286 having a recess (not shown), and a back wall portion 294 having a protrusion 296 .
- the right connector housing 278 may have a front wall portion 298 having a recess (not shown), a right side wall 304 having a recess 306 , and a back wall portion 308 having a protrusion (not shown).
- the left side wall 286 and the right sidewall 304 may also extend below their respective front wall portions and back wall portions. Each extended portion may have a recess 314 and 316 respectively, capable of receiving the first protrusion 260 and second protrusion 268 extending from the left side 264 and right side 270 respectively of the tail alignment housing 252 .
- the housing is not limited to such a design and may include other configurations.
- an embodiment of the left connector housing 274 may be placed onto the complete assembly 240 , interlocking the left connector housing 274 to the edge card housing 180 .
- the first protrusion 196 (as shown in FIG. 7A ) extending from the left side of the edge card body 194 may interlock with the recess formed in the left side wall 286 of the left connector housing 274 .
- a portion of the third protrusion 204 extending from the bottom of the edge card body 194 may interlock with the recess formed in the front wall portion 280 (shown in FIG. 15 ) of the left connector housing 274 .
- the protrusion 296 extending from the back wall portion 294 of the left connector housing 274 may interlock with a portion of the recess 208 formed in the back side of the edge card body 194 .
- the connection with the back side of the edge card body 194 may have a tongue and groove fit.
- the recess 314 formed in the extended portion of the left sidewall 286 may interlock with the protrusion 260 extending from the left side 264 of the tail alignment housing 252 .
- an embodiment of the right connector housing 278 may be placed onto the complete assembly 240 , interlocking the right connector housing 278 to the edge card housing 180 .
- the second protrusion 200 extending from the right side of the edge card body 194 may interlock with the recess 306 formed in the right side wall 304 of the right connector housing 278 .
- a portion of the third protrusion 204 (as shown in FIG. 7A ) extending from the bottom of the edge card body 194 may interlock with the recess formed in the front wall portion 298 (shown in FIG. 15 ) of the right connector housing 278 .
- the protrusion extending from the back wall of the right connector housing 278 may interlock with a portion of the recess 208 (shown in FIG. 7B ) formed in the back side of the edge card body 194 .
- the connection with the back side of the edge card body 194 may have a tongue and groove fit.
- the recess 316 formed in the extended portion of the right sidewall 304 may interlock with the protrusion 268 extending from the right side 270 of the tail alignment housing 252 .
- FIG. 15 depicts a front view of an embodiment of a completed connector 320 .
- the front wall 280 of the left connector housing 274 and the front wall 298 of the right connector housing 278 may be seen.
- extra strength may be added to the edge card housing 180 to help withstand the force of “overmating.”
Abstract
Description
- This application is related to application number (Attorney Docket No. FCI-3027 (C4060)), filed concurrently herewith.
- The invention relates generally to electrical connectors. More particularly, the invention relates to connectors having tails.
- Advanced Mezzanine Cards are printed circuit boards (PCBs) that follow a specification of the PCI Industrial Computers Manufacturers Group (PICMG). PICMG AMC connectors may be used in accordance with such a specification. Typically, manufacturers of such connectors mold the contacts in a vertical (or “column”) direction. Accordingly, each column of contacts is molded into a separate leadframe assembly. In some such connectors, as many as 80 or more contact columns are required. Consequently, a relatively large number of individual insert molded leadframe assemblies (IMLAs) may be required to make such a connector.
- Due to the number of separate IMLAs required to make such a connector, manufacturers have proposed insert molding the contacts into a plurality of horizontal arrays, or “rows.” With such connectors, however, there are problems with controlling the positioning and straightness of the mounting ends of the electrical contacts (i.e., the contact “tails”) in a cost-effective manner.
- The invention provides a connector that incorporates a tail-alignment housing that may control the position of the mounting, or “tail,” ends. The tail-alignment housing may also provide a structure that helps absorb the forces required for press fitting the connector to a printed circuit board (PCB). The tail-alignment housing may have a housing body and a plurality of tail supports extending from the housing body up and around the contact tails.
- In one embodiment, such a connector may include a first leadframe assembly having a first plurality of contacts, a second leadframe assembly having a second plurality of contacts, an edge card, and a tail-alignment housing. Each contact may include a lead portion and a mounting end. The lead portions of the contacts may engage the edge card. The tail-alignment housing may include a housing body and a plurality of tail supports extending from the housing body. The tail alignment housing may be overmolded onto the contact mounting ends.
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FIG. 1 is an isometric view of an embodiment of a first leadframe of electrical contacts as stamped and plated. -
FIG. 2 is an isometric view of a first leadframe assembly after molding. -
FIG. 3 is an isometric view of the leadframe assembly ofFIG. 2 after forming and slugout. -
FIG. 4 is an isometric view of an embodiment of a second leadframe of electrical contacts as stamped and plated. -
FIG. 5 is an isometric view of a second leadframe assembly after molding. -
FIG. 6 is an isometric view of the leadframe assembly ofFIG. 5 after forming and slugout. -
FIGS. 7A and 7B are isometric views of an embodiment of an edge card housing. -
FIG. 8 is an isometric view of an embodiment of a complete assembly prior to insertion into the edge card housing. -
FIG. 9 is an isometric view of the complete assembly ofFIG. 8 with an edge card housing added. -
FIG. 10 depicts the complete assembly ofFIG. 9 after a second overmold process. -
FIGS. 11A and 11B are isometric views of a portion of the complete assembly ofFIG. 10 . -
FIG. 12 is a cross-sectional view of the complete assembly ofFIG. 10 -
FIG. 13 is an isometric view of the complete assembly ofFIG. 10 with a left connector housing added. -
FIG. 14 is an isometric view of the complete assembly ofFIG. 13 with a right connector housing added. -
FIG. 15 is an isometric view of an embodiment of a complete connector. - A
first embodiment leadframe 10 ofelectrical contacts 14 may be stamped from a sheet of electrically conductive material, such as copper alloy, for example.FIG. 1 depicts theleadframe 10 ofelectrical contacts 14 attached to one another and to acarrier frame 18. Eachcontact 14 may include amating end 22, amating portion 26, afirst housing portion 28, alead portion 29, asecond housing portion 30, athird housing portion 32, amounting portion 34, and amounting end 36. Thelead portions 29 of the contacts may be attached to one another via “bridges” that remain after stamping. The mounting ends 36 of the contacts may each include atail 38. Thecontacts 14 may be selectively gold plated. - Once the
leadframe 10 has been stamped, afirst leadframe housing 42 may be overmolded onto thefirst housing portions 28 of thecontacts 14. Asecond leadframe housing 46 may be overmolded onto thesecond housing portions 30 of the contacts. Each leadframe housing may be made of a dielectric material, such as a plastic. Both housings may be overmolded onto theleadframe 10 in a single molding process using well-known techniques. -
FIG. 2 depicts afirst leadframe assembly 48 after thefirst leadframe housing 42 and thesecond leadframe housing 46 have been overmolded onto theelectrical contacts 14, with thecarrier frame 18 shown inFIG. 1 removed. As shown, alinear array 50, or “row,” ofelectrical contacts 14 may extend through each of thefirst leadframe housing 42 and thesecond leadframe housings 46. - The
second housing 46 may include one ormore interlock members 54. As shown, eachinterlock member 54 may be aprotrusion 58 that extends from aface 60 of thehousing 46, or arecess 62 defined by theleadframe housing 46. Eachrecess 62 is adapted to receive a complementary protrusion extending from a leadframe housing of a second leadframe assembly and eachprotrusion 58 is adapted to be received in a complementary recess defined by the leadframe housing of the second leadframe assembly. Theinterlock members 54 will be described in more detail in connection withFIG. 8 . - After the leadframe housings are overmolded onto the
leadframe 10, the bridges that attach thecontacts 14 to one another may be “slugged out.” Thecontacts 14 may be formed into any desired shape.FIG. 3 depicts an example embodiment of aleadframe assembly 48 after slug out and formation of thecontacts 14. As shown, thelead portions 29 may be bent to a first angle (e.g., 90°) at afirst bend point 66, to a second angle (e.g., 90°) at asecond bend point 70, and to a third angle (e.g., 90°) at athird bend point 74. Thus, thelead portions 29 may be bent to include respective C-shaped portions that culminate in therespective mating portions 26 of thecontacts 14. Consequently, themating portions 26 of thecontacts 14 may extend along a plane that is generally perpendicular to the plane along which the mountingportions 34 of thecontacts 14 extend. In other words, themating portions 26 of thecontacts 14 may extend generally perpendicular to the mountingportions 34 of thecontacts 14. - A
second embodiment leadframe 110 ofelectrical contacts 114 may be stamped from a sheet of electrically conductive material, such as copper alloy, for example.FIG. 4 , depicts theleadframe 110 ofelectrical contacts 114 attached to one another and to a carrier frame 1 18. Eachcontact 114 may include amating end 122, amating portion 126, afirst housing portion 128, alead portion 129, asecond housing portion 130, athird housing portion 132, a mountingportion 134, and a mountingend 136. Thelead portions 129 of thecontacts 114 may be attached to one another via “bridges” that remain after stamping. The mounting ends 136 of thecontacts 114 may each include atail 138. Thecontacts 114 may be selectively gold plated. - After the
leadframe 110 has been stamped, afirst leadframe housing 142 may be overmolded onto thefirst housing portions 128 of thecontacts 114. Asecond leadframe housing 146 may be overmolded onto thesecond housing portions 130 of thecontacts 114. Eachleadframe housing 142/146 may be made of a dielectric material, such as a plastic. Both thefirst leadframe housing 142 and thesecond leadframe housing 146 may be overmolded onto theleadframe 110 in a single molding process using well-known techniques. -
FIG. 5 depicts asecond leadframe assembly 148 after thefirst leadframe housing 142 and thesecond leadframe housing 146 have been overmolded onto theelectrical contacts 114, with thecarrier frame 118 shown inFIG. 4 removed. As shown, alinear array 150, or “row,” ofelectrical contacts 114 may extend through each of thefirst leadframe housing 142 and thesecond leadframe housing 146. - The
second housing 146 may include one or more interlock members similar to those described in connection withFIG. 2 . As described above in connection withFIG. 2 , each interlock member may be a protrusion that extends from a face of the second leadframe housing, or a recess defined by the second leadframe housing. Each recess may be adapted to receive thecomplementary protrusion 58 extending from thesecond leadframe housing 46 of the first leadframe assembly 48 (seeFIG. 3 ), and each protrusion may be adapted to be received in acomplementary recess 62 defined by thesecond leadframe housing 46 of the first leadframe assembly 48 (seeFIG. 3 ). The interlock members will be described in more detail in connection withFIG. 8 . - After the
first leadframe housing 142 and thesecond leadframe housing 146 are overmolded onto theleadframe 110, the bridges that attach thecontacts 114 to one another may be “slugged out.” Thecontacts 114 may be formed into any desired shape.FIG. 6 depicts an example embodiment of theleadframe assembly 148 after slug out and formation of thecontacts 114. As shown, thelead portions 129 may be bent to an angle (e.g., 90°) at abend point 155. Thus, thelead portions 129 may be bent to include respective L-shaped portions that culminate in therespective mating portions 126 of the contacts 1 14. Consequently, themating portions 126 of thecontacts 114 may extend along a plane that is generally perpendicular to the plane along which the mountingportions 134 of thecontacts 114 extend. In other words, themating portions 126 of thecontacts 114 may extend generally perpendicular to the mountingportions 134 of thecontacts 114. - The
mating portions 26 of thefirst leadframe assembly 48 and themating portions 126 of thesecond leadframe assembly 148 may then be inserted into anedge card housing 180.FIGS. 7A and 7B depict an exampleedge card housing 180. Theedge card housing 180 may be made of a dielectric material, such as a plastic. Theedge card housing 180 may include a row ofreceptacles 184, acard slot 190, anedge card body 194, afirst protrusion 196 extending from the left side of theedge card body 194, asecond protrusion 200 extending from the right side of theedge card body 194, athird protrusion 204 extending from the bottom of theedge card body 194 and arecess 208 formed in the back side of theedge card body 194. The first 196, second 200, and third 204 protrusions may be capable of being received by recesses formed in a connector housing. Therecess 208 may be capable of receiving a protrusion extending from a connector housing. The housing will be explained in more detail in connection withFIGS. 13 and 14 . In the embodiment shown inFIGS. 7A and 7B , thefirst protrusion 196 and thesecond protrusion 200 may each consist of two snap-fit members, and thethird protrusion 204 may consist of a T-beam or dove tail. Therecess 208 formed in the back side may be a slot. Theedge card 180 is not limited to the disclosed embodiment and may incorporate different designs and structures. -
FIG. 8 depicts an embodiment of thefirst leadframe assembly 48 and thesecond leadframe assembly 148 interlocked together creating acomplete assembly 240. Each recess 62 (as shown inFIG. 3 ) of thefirst leadframe assembly 48 may receive the respective protrusion from thesecond leadframe assembly 148 and each recess of thesecond leadframe assembly 148 may receive the respective protrusion 58 (as shown inFIG. 3 ) from thefirst leadframe assembly 48. As shown, thefirst leadframe housing 142 of thesecond leadframe assembly 148 may rest on or connect to thefirst leadframe housing 42 of thefirst leadframe assembly 48. When thefirst leadframe assembly 48 and thesecond leadframe assembly 148 are combined, the mountingportions 34/134 of each leadframe assembly may be parallel. - The
first leadframe assembly 48 may be inserted into theedge card housing 180. That is, themating portions 26 of thecontacts 14 of thefirst leadframe assembly 48 may be received into the row ofreceptacles 184 defined by theedge card housing 180. - The
second leadframe assembly 148 may be inserted into theedge card housing 180. That is, themating portions 126 of thecontacts 114 of thesecond leadframe assembly 148 may be received into the row ofreceptacles 184 defined by theedge card housing 180.FIG. 9 depicts an embodiment of thecomplete assembly 240 with both leadframe assemblies inserted into an exampleedge card housing 244. - After the leadframe assemblies have been inserted into the
edge card housing 180, atail alignment housing 250 may be overmolded onto thethird housing portions 32/132 of thecontacts 14/114, using well-known injection molding techniques. Thetail alignment housing 250 may be made of a dielectric material, such as a plastic.FIG. 10 depicts an embodiment of thecomplete assembly 240 after the second overmold process. As shown, thetail alignment housing 250 may extend up a portion of the mounting ends 36/136 (as shown inFIG. 12 ) of both leadframe assemblies. Therefore, thetail alignment housing 250 may serve to control the position of thetails 38/138 of the mounting ends 36/136 and may provide a structure to transfer the forces for press fit of the connector to the PCB. - As shown in
FIGS. 11A and 11B , an embodiment of atail alignment housing 252 may include a plurality of tail supports 254 extending from abody 258 of thetail alignment housing 252 up and around the mounting ends 36/136, that may help further control the position of thetails 38/138 and may provide further structure to the connector. The tail supports 254 may take the shape of pyramids, as shown inFIGS. 11A and 11B but are not limited to such a design. For example, the supports may also be cones, squares, rectangles, or any other designs capable of controlling the position of thetails 38/138. Thetail alignment housing 252 may also have afirst protrusion 260 extending from aleft side 264 and a second protrusion 268 (shown inFIG. 13 ) extending from aright side 270. The protrusions may be received by recesses formed in the connector housing. -
FIG. 12 depicts a cross-sectional view of thecomplete assembly 240 after the second overmold process, showing how the contacts may be oriented within theedge card 244, and thetail alignment housing 250. As shown, themating portions 26 of thefirst leadframe assembly 48 may angle in a substantially upward direction within theedge card 244, and themating portions 126 of thesecond leadframe assembly 148 may angle in a substantially downward direction within theedge card 244. Furthermore the mating ends 22 of thefirst leadframe assembly 48 may angle in a substantially downward direction, and the mating ends 122 of thesecond leadframe assembly 148 may angle in a substantially upward direction. Generally, the mating ends may extend toward the card slot of theedge card 244. Also shown inFIG. 12 , are the orientations of the mounting ends 36/136 of thefirst leadframe assembly 48 and of thesecond leadframe assembly 148 within thetail alignment housing 252. - A connector housing may also be added to the complete assembly. The connector housing may be made of a dielectric material such as a plastic. In one embodiment, the connector housing may be separated into two pieces; a
left connector housing 274 and aright connector housing 278. Theleft connector housing 274 may have afront wall portion 280 having a recess (not shown), aleft side wall 286 having a recess (not shown), and aback wall portion 294 having aprotrusion 296. Theright connector housing 278 may have afront wall portion 298 having a recess (not shown), aright side wall 304 having arecess 306, and aback wall portion 308 having a protrusion (not shown). Theleft side wall 286 and theright sidewall 304 may also extend below their respective front wall portions and back wall portions. Each extended portion may have arecess first protrusion 260 andsecond protrusion 268 extending from theleft side 264 andright side 270 respectively of thetail alignment housing 252. The housing is not limited to such a design and may include other configurations. - As shown in
FIG. 13 , an embodiment of theleft connector housing 274 may be placed onto thecomplete assembly 240, interlocking theleft connector housing 274 to theedge card housing 180. The first protrusion 196 (as shown inFIG. 7A ) extending from the left side of theedge card body 194 may interlock with the recess formed in theleft side wall 286 of theleft connector housing 274. A portion of thethird protrusion 204 extending from the bottom of theedge card body 194 may interlock with the recess formed in the front wall portion 280 (shown inFIG. 15 ) of theleft connector housing 274. Theprotrusion 296 extending from theback wall portion 294 of theleft connector housing 274 may interlock with a portion of therecess 208 formed in the back side of theedge card body 194. The connection with the back side of theedge card body 194 may have a tongue and groove fit. Therecess 314 formed in the extended portion of theleft sidewall 286 may interlock with theprotrusion 260 extending from theleft side 264 of thetail alignment housing 252. - As shown in
FIG. 14 , an embodiment of theright connector housing 278 may be placed onto thecomplete assembly 240, interlocking theright connector housing 278 to theedge card housing 180. Thesecond protrusion 200 extending from the right side of theedge card body 194 may interlock with therecess 306 formed in theright side wall 304 of theright connector housing 278. A portion of the third protrusion 204 (as shown inFIG. 7A ) extending from the bottom of theedge card body 194 may interlock with the recess formed in the front wall portion 298 (shown inFIG. 15 ) of theright connector housing 278. The protrusion extending from the back wall of theright connector housing 278 may interlock with a portion of the recess 208 (shown inFIG. 7B ) formed in the back side of theedge card body 194. The connection with the back side of theedge card body 194 may have a tongue and groove fit. Therecess 316 formed in the extended portion of theright sidewall 304 may interlock with theprotrusion 268 extending from theright side 270 of thetail alignment housing 252. -
FIG. 15 depicts a front view of an embodiment of a completedconnector 320. Thefront wall 280 of theleft connector housing 274 and thefront wall 298 of theright connector housing 278 may be seen. By having theright connector housing 278 and theleft connector housing 274 interlock with theedge card housing 180, extra strength may be added to theedge card housing 180 to help withstand the force of “overmating.”
Claims (26)
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US11/677,449 US7744380B2 (en) | 2007-02-21 | 2007-02-21 | Overmolded electrical contact array |
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US11/677,449 US7744380B2 (en) | 2007-02-21 | 2007-02-21 | Overmolded electrical contact array |
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US7744380B2 US7744380B2 (en) | 2010-06-29 |
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